Husqvarna Chain Saws PDF

Husqvarna Chain Saws
Workshop Manual
101 88 55-26
Eng, front 1 96-09-13, 10.38

LIST OF CONTENTS
Introduction ..................................... 3
Safety regulations ........................... 5
Technical Data ................................. 6
Tools ............................................... 14
Service data ................................... 20
Trouble shooting ........................... 40
Safety equipment .......................... 42
Starter ............................................. 57
Electrical system ........................... 61
Centrifugal clutch .......................... 67
Lubrication system ....................... 70
Carburettor..................................... 83
Air filter ........................................ 101
Tank unit....................................... 103
Anti-vibration system.................. 106
Piston cylinder............................. 108
Crankcase and crankshaft.......... 114
2 English
Eng, p 2-39 2 96-09-13, 09.05

INTRODUCTION
General Updates
This workshop manual provides a detailed de- As production continues, changes will be intro-
scription of procedures for trouble shooting, repair duced successively to the chain saw. If at any
and testing of the chain saws. Safety precautions time these changes influence service and/or
that should be taken during repair are also spares, special service announcements will be
described. sent out, which means that this manual will cease
to be current with time. In order to avoid prob-
This workshop manual applies to the engine lems, the manual should always be read together
assembly in the following chain saws: with all service announcements that apply to the
specific model of chain saw.
36 257
40 262XP
268 Tools
41
For specific procedures special tools are re-
42 272XP quired. In this workshop manual, all the service
268K tools required are listed. Use of the tools is
45 272K described in appropriate sections.
51 272S
55 Always use Husqvarna original:
61 281XP
Spare parts
288XP Service tools
242XP Accessories
246 394XP
254XP 3120XP
Layout
Safety The descriptive sections in this workshop manual
Note! are set out in a number of flow diagrams. When
The section dealing with safety should be carrying out repairs on a specific chain saw,
read and understood by all who carry out follow the signs that apply to the saw in question.
repair or service work on the chain saw.
Diagrams are not numbered as they are linked to
There are warning symbols on the chain saw. If a the actual text, either by lines or by being in the
warning symbol has been damaged or is missing, same box.
it must be replaced immediately in order to
maximise safety when the saw is in use. Positional directives to components inside the
diagrams are designated with A, B, etc. and start
from A again in each new section.
Target group
This workshop manual is written for personnel

that are assumed to have general knowledge of
service and repair of small engines.
The workshop manual should be read and under-

stood by all personnel carrying out service and
repair work on the chain saw. The manual is also
suitable for use in the training of new employees.
English 3
Eng, p 2-39 3 96-09-13, 09.05

INTRODUCTION
Use Dismantling and reassembly of the entire
chain saw
This workshop manual can be used in two different
ways: When the entire chain saw is to be dismantled
and reassembled, proceed as follows:
Repair of a specific sub-assembly
Dismantling and reassembly of the entire chain 1. Refer to page 57, which deals with the
saw Starter and carry out the instructions
under the heading Dismantling.
Repair of a specific sub-assembly
2. Work forwards through the manual and
When a specific sub-assembly on the chain saw is carry out Dismantling instructions in the
to be repaired, proceed as follows: order that the sections occur.
1. Refer to the page referring to the relevant sub- 3. Return to the Starter on page 58 and
assembly. follow the instructions under Cleaning
and Inspection.
2. Carry out the steps: Dismantling
Cleaning and inspection 4. Work forward through the manual and
Reassembly carry out Cleaning and Inspection in the
order that the sections occur.
5. Order or collect all the required spare

parts from the spare parts stores.
6. In order to Assemble the chain saw,

proceed as follows:
Refer to pages 117-120 which deals with

the Crankcase and carry out the instruc-
tions under Assembly.
Refer to pages 111-112 which deals with

the Piston and Cylinder and carry out
the instructions under Assembly.
Refer to pages 107 which deals with the

Anti-vibration system and carry out the
instructions under Assembly.
Refer to page 105 which deals with the

Tank unit and carry out the instructions
under Assembly.
Continue to work backwards through the

manual and carry out Assembly instructions
as the sections occur.
In order to improve understanding, some

sections begin with a Description of the
relevant sub-assembly.
4 English
Eng, p 2-39 4 96-09-13, 09.05

SAFETY REGULATIONS
General Instructions Special instructions
Workshops where chain saws are serviced The fuel used in the chain saw poses the
must be equipped with safety equipment following hazards:
as set out in local directives. 1. The fluid and its fumes are poisonous.
2. Can cause eye and skin irritation.
No one should repair a chain saw without 3. Can cause breathing difficulties
first having read and understood the 4. Is highly inflammable.
contents of this workshop manual.
The bar, chain and clutch cover (chain
The following warning texts are to be found brake) must be assembled before the
in this manual in certain places. The chain saw is started, otherwise the clutch
warning texts occur before the procedure may come loose causing personal injury.
to which they refer.
Wear ear muffs when testing the chain
saw.
!
Do not use the saw until it has been
WARNING! adjusted so that the chain does not rotate
The warning text indicates a risk
of personal injury if instructions when idling.
are not followed.
Bear in mind the fire risk. The saw can
produce sparks that can cause a fire hazard..
1
After testing, do not touch the
NOTE!
The warning text indicates a risk of silencer until it has cooled. Risk
damage to equipment if instructions of burns. This especially applies if
are not followed. the saw is fitted with a catalytic converter.
The coating on and in the catalytic element
is hazardous to touch. Use protective gloves
when working on the catalytic converter.
The chain saw is type approved with
regard to safety according to applicable Inadequate chain lubrication can result in
legal requirements when fitted with the the chain breaking, which can cause
cutting equipment specified in the serious or fatal injury.
Operator's Manual. Equipping the saw with
other equipment or accessories and spare Make sure that the starter recoil
parts not approved by Husqvarna can spring does not fly out and cause
result in non compliance with these safety personal injury. Release the spring
requirements and liability for persons tension before the cord pulley is removed.
carrying out such modifications.
When removing the pressure
spring for the chain brake, ensure
that the brake is in the 'on'
position which reduces the spring
tension, otherwise the spring can fly out
causing personal injury.
After repair, the chain brake must be
checked in accordance with the
instructions on page 47.
When replacing the crankshaft bearings
note that the crankcase halves are hot.
Use protective gloves.
When using compressed air, the air jet
should never be pointed towards the body.
Air can be forced into the blood stream,
which can cause fatality.
English 5
Eng, p 2-39 5 96-09-13, 09.05

TECHNICAL DATA
Displacement Bore Stroke Max. power at

cm3 mm mm r/min
36 36 38.0 32.0 9000
40 40 40.0 32.0 9000
41 40 40.0 32.0 9000
42 42 42.0 30.0 9300

45 44 42.0 32.0 9000
51 51 45.0 32.0 9000
Spark plug gap Ignition system Air gap Carburettor

mm/inches mm/inches
36 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239
40 0.5/ .02 PHELON 0.3/ .012 ZAMA C1Q-EL1
41 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239
42 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98

45 0.5/ .02 PHELON 0.3/ .012 ZAMA C1Q-EL1
51 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170
Bar length Chain speed Chain pitch Drive link gauge

cm/inches m/s inches mm/inches
36 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050

40 33-46/13-18 17.4/8500 rpm .325 1.3/ .050
41 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050
42 28-46/11-18 17.9/9300 rpm .325 1.5/ .058 / 1.3/ .0501)

45 33-46/13-18 17.4/8500 rpm .325 1.3/ .050
51 33-51/13-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .0501)
1)
From May 1996
6 English
Eng, p 2-39 6 96-09-13, 09.05

TECHNICAL DATA
Idling speed Engagement speed Max. speed Spark plug

r/min r/min r/min Champion
36 3000 4500 13000 RCJ 7 Y
40 2500 3600 12500 RCJ 7 Y
41 3000 4500 13000 RCJ 7 Y
42 2700 3800 14500 RCJ 7 Y

45 2500 3600 12500 RCJ 7 Y
51 2500 3700 12500 RCJ 7 Y
Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump
3
Litres cm /min at 8.500 rpm Litres
36 0.4 7 0.2 Yes

40 0.5 8 0.25 Yes
41 0.4 7 0.2 Yes
42 0.5 3-7 0.27 Yes

45 0.5 8 0.25 Yes
51 0.6 10 0.3 Yes
Weight without bar and chain Weight with bar and chain Handle heater
kg kg/lbs Watt/ r/min
36 4.6 5.3 (13") No

40 4.7 5.4 (13") No
41 4.6 5.3 (13") No
42 4.7 5.5 (13") No

45 4.7 5.4 (13") No
51 5.2 6.2 (15") No
English 7
Eng, p 2-39 7 96-09-13, 09.05

TECHNICAL DATA

cm3 mm mm r/min
55 53 46.0 32.0 9000
61 62 48.0 34.0 8300
242XP 42 42.0 30.0 9900
246 46 44.0 30.0 9000

254XP 54 45.0 34.0 9300
257 57 46.0 34.0 9000

mm/inches mm/inches
55 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170
61 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 254
242XP 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98
246 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98

254XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 35B
257 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 120

55 38-51/15-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .050 1)

61 38-51/15-20 18.4/8300 rpm 3/8 1.5/ .058
242XP 28-46/11-18 19.1/9900 rpm .325 1.5/ .058 / 1.3/ .050 1)
246 28-46/11-18 17.3/9000 rpm .325 1.5/ .058 / 1.3/ .050 1)

254XP 33-51/13-20 17.3/9300 rpm .325-3/8 1.5/ .058
257 33-51/13-20 17.3/9000 rpm .325-3/8 1.5/ .058
1)
From May 1996
8 English
Eng, p 2-39 8 96-09-13, 09.05

TECHNICAL DATA

55 2500 3700 12500 RCJ 7 Y
61 2500 3700 12000 RCJ 7 Y
242XP 2700 3900 15500 RCJ 7 Y
246 2700 3900 15000 RCJ 7 Y

254XP 2700 3700 13800 RCJ 7 Y
257 2700 3700 13500 RCJ 7 Y
Litres cm3/min at 8.500 rpm Litres
55 0.6 10 0.3 Yes

61 0.75 4/8/12/17 0.45 Yes
242XP 0.5 3-7 0.27 Yes
246 0.5 3-7 0.27 Yes

254XP 0.6 3-10 0.3 Yes
257 0.6 3-10 0.3 Yes
Weight without bar and chain Weight with bar and chain Handle heater
55 5.2 6.2 (15") No

61 6.1 7.1 (15") No
242XP 4.7 5.5 (13") 65/10.000
246 4.7 5.5 (13") No

254XP 5.4 6.3 (13") 65/10000
257 5.6 6.6 (13") 65/10000
English 9
Eng, p 2-39 9 96-09-13, 09.05

TECHNICAL DATA
Displacemennt Bore Stroke Max. power at

cm3 mm mm r/min
262XP 62 48.0 34.0 9600
268 67 50.0 34.0 9000
272XP 72 52.0 34.0 9300
268K 67 50.0 34.0 9000

272K 72 52.0 34.0 9300
272S 72 52.0 34.0 9300

mm/inches mm/inches
262XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 120
268 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 260
272XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 260
268K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255

272K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255
272S 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255

262XP 33-51/13-20 18.5/9600 rpm .325-3/8 1.5/ .058

268 38-51/15-20 18.4/9000 rpm 3/8 1.5/ .058
272XP 38-51/15-20 20.0/9300 rpm 3/8 1.5/ .058
268K - - - -
272K - - - -
272S - - - -
10 English
Eng, p 2-39 10 96-09-13, 09.05

TECHNICAL DATA

262XP 2700 3400 13500 RCJ 7 Y
268 2500 3500 12500 RCJ 7 Y
272XP 2500 3500 13500 RCJ 7 Y
268K 2500 3500 10000 RCJ 7 Y

272K 2500 3500 10000 RCJ 7 Y
272S 2500 3500 10000 RCJ 7 Y
262XP 0.6 6.5-13.5 0.3 Yes

268 0.75 4/9/13/17 0.45 Yes
272XP 0.75 5/9/14/19 0.45 Yes
268K 0.75 - - -
272K 0.75 - - -
272S 0.75 - - -
Weight without chain and bar Weight with chain and bar Handle heater
262XP 5.8 6.8 (13") 65/10000

268 6.2 7.2 (15") 65/10000
272XP 6.3 7.3 (15") 65/10000
268K 9.5 - -
272K 9.6 - -
272S 21.0 (including carriage) - -
English 11
Eng, p 2-39 11 96-09-13, 09.43

TECHNICAL DATA

cm3 mm mm r/min
281XP 81 52.0 38.0 9000
288XP 87 54.0 38.0 9300
394XP 94 56.0 38.0 8800

3120XP 119 60.0 42.0 9000

mm/inches mm/inches
281XP 0.5/ .02 SEM AM 7 0.3/ .012 TILLOTSON HS 228
288XP 0.5/ .02 SEM AM 7 0.3/ .012 TILLOTSON HS 228
394XP 0.5/ .02 SEM AM 44 0.3/ .012 WALBRO WJ 39

3120XP 0.5/ .02 SEM AM 37 0.3/ .012 WALBRO WG 6

281XP 38-71/15-28 20.0/9000 rpm 3/8 1.5/ .058

288XP 38-71/15-28 20.7/9300 rpm 3/8 1.5/ .058
394XP 46-91/18-36 19.6/8800 rpm 3/8-.404 1.5/ .058 - 1.6/.063

3120XP 60-107/24-42 20.1/9000 rpm .404 1.6/ .063
12 English
Eng, p 2-39 12 96-09-13, 09.43

TECHNICAL DATA

281XP 2500 3200 12500 RCJ 6 Y
288XP 2500 3200 12500 RCJ 6 Y
394XP 2500 3400 12500 RCJ 6 Y

3120XP 2500 3300 11500-12500 RCJ 7 Y
281XP 0.9 9/12/15/18 0.5 Yes

288XP 0.9 9/12/15/18 0.5 Yes
394XP 0.9 14-21 0.5 Yes

3120XP 1.25 8-51 0.7 Yes
Weight without bar and chain Weight with bar chain Handle heater
281XP 7.5 8.7 (18") 56/7200

288XP 7.5 8.7 (18") 56/7200
394XP 7.9 9.2 (18") 65/10000

3120XP 10.4 12.3 (28") No
English 13
Eng, p 2-39 13 96-09-13, 09.43

TOOLS
Tools for all chain saws
502 50 57-01 3/16"

502 50 16-01 6 mm
502 50 64-01 5 mm
502 50 18-01 4 mm
502 50 22-01 8 mm
502 50 19-01 3 mm
502 50 23-01 10 mm
502 50 88-01 5 mm
502 50 87-01 4 mm
502 50 86-01 3 mm
502 71 13-01
504 98 26-01
502 50 06-01 (36, 41, 40, 45)
502 51 34-02 (0,3 mm)

502 51 91-01 (0,5 mm)
502 50 83-01
502 50 37-01
502 70 09-01
compl 502 50 70-01
502 51 02-01
502 71 14-01
14 English
Eng, p 2-39 14 96-09-13, 09.44

TOOLS
Tools for saws 36 and 41 Tools for saws 40, 45, 51 and 55
3 mm; 4 mm; 5 mm 4 mm
8 mm; 10 mm 8 mm
502 50 33-01 502 50 33-01
505 26 79-12
40 > 910 1116
45 > 925 1168
502 51 94-01 50 > 925 0856 502 51 94-01
530 03 11-12 530 03 11-36 502 50 99-01 502 50 26-01 505 38 18-17
(55) (55) (40. 45)
502 51 00-02
502 51 61-01
(51, 55)
504 90 90-01
502 50 30-09
40 > 910 1116 502 50 79-01 (55)
45 > 925 1168
compl 502 50 38-01
502 54 03-01
(40, 45, 55)
504 90 29-02 502 50 46-01

(55)
English 15
Eng, p 2-39 15 96-09-13, 09.45

TOOLS
Tools for saws 42, 242 and 246 Tools for saws 254, 257 and 262
3 mm; 4 mm 3 mm; 4 mm
8 mm 8 mm
502 50 33-01 502 50 33-01
*compl 502 51 49-02 *compl 502 51

49-02
502 51 49-01* 502 51 49-01*
*502 51 54-01 *502 51 54-01
502 50 26-01* 502 50 26-01*

502 50 99-01
502 50 99-01
502 70 03-01
compl 502 50 31-01 502 51 61-01 504 90 90-01
502 51 61-01
504 90 90-01
502 50 82-01
502 50 30-07
502 51 32-01 502 51 50-01

502 50 79-01
502 50 30-10
502 51 00-02
compl 502 50 38-01 compl 502 50 38-01
502 50 45-01 502 50 45-01

502 50 72-01 502 50 72-01
502 50 46-01 502 50 46-01

502 50 71-01 502 50 71-01
16 English
Eng, p 2-39 16 96-09-13, 09.46

TOOLS
Tools for saws 61, 268 and 272 Tools for saws 281 and 288
3 mm; 4 mm; 3/16" 3 mm; 4 mm; 3/16"
8 mm 502 71 36-01 (4 mm) 8 mm 502 71 36-01 (4 mm)
502 50 33-01 502 50 33-01
*compl 502 51 49-02 *compl 502 51 49-02
502 51 49-01* 502 51 49-01*
*502 51 54-01 *502 51 54-01
502 50 26-01* 502 50 26-01*
502 70 03-01
compl 502 50 31-01 502 51 61-01 504 90 90-01 502 51 61-01 504 90 90-01
502 51 69-01 502 50 82-01

(268)
502 50 30-04
502 50 30-08
502 50 53-01 502 50 52-01
502 50 66-02
502 50 67-01
502 51 00-02
502 50 66-02
compl 502 50 38-01 compl 502 50 38-01
502 50 45-01
502 50 47-01 502 50 47-01
502 50 46-01
502 50 46-01
502 50 48-01 502 50 81-01
502 50 20-01
English 17
Eng, p 2-39 17 96-09-13, 09.47

TOOLS
Tools for saws 394 and 3120
3 mm; 4 mm; 5 mm; 3/16"
8 mm; 10 mm
502 50 33-01
*compl 502 51 49-02
502 51 49-01*
*502 51 54-01
502 50 26-01*
504 90 90-01
502 50 82-01
502 50 52-01
502 50 30-08
502 50 66-02
compl 502 50 38-01
502 52 04-01
502 52 01-01 (394) (394)
502 71 38-01 (3120) 502 71 40-01
(3120)
502 71 39-01 (394)
18 English
Eng, p 2-39 18 96-09-13, 09.48

TOOLS
List of tools
Order number Designation Order number Designation
502 50 06-01 Pliers 502 51 49-01 Puller

502 50 16-01 Allen key 502 51 49-02 Puller
502 50 18-01 Allen key 502 51 50-01 Socket
502 50 19-01 Allen key 502 51 54-01 Bolt set
502 50 20-01 Assembly tool 502 51 61-01 Dismantling tool, crankcase
502 50 22-01 Socket 502 51 69-01 Assembly mandrel

502 50 23-01 Socket 502 51 69-01 Feeler gauges
502 50 26-01 Puller 502 51 94-01 Assembly mandrel
502 50 30-04 Assembly tool 502 52 01-01 Cover plate
502 50 30-08 Assembly tool 502 52 04-01 Spacer
502 50 30-09 Assembly tool 502 54 03-01 Spacer

502 50 30-10 Assembly tool 502 70 09-01 Pump blower
502 50 31-01 Puller 502 71 13-01 Test spark plug
502 50 33-01 Piston stop 502 71 14-01 Tachometer
502 50 37-01 Vacuum gauge 502 71 36-01 Allen key
502 50 38-01 Pressure gauge 502 71 38-01 Cover plate

502 50 45-01 Extended socket 502 71 39-01 Cover plate
502 50 46-01 Extended socket 502 71 40-01 Spacer
502 50 47-01 Cover plate 504 90 29-02 Cover plate
502 50 48-01 Cover plate 504 90 90-01 Puller
502 50 52-01 Assembly socket 504 98 26-01 Silicone rubber

502 50 57-01 Allen key 505 26 79-12 Assembly mandrel
502 50 64-01 Allen key 505 38 18-17 Puller
502 50 66-02 U-key
502 50 67-01 U-key
502 50 70-01 Assembly tool, piston

502 50 71-01 Cover plate
502 50 79-01 Assembly mandrel
502 50 82-01 Assembly mandrel

502 50 83-01 Hook, tank valve
502 50 86-01 Allen key
502 50 87-01 Allen key
502 50 88-01 Allen key
502 50 99-01 Puller sleeve

502 51 00-02 U-key
502 51 02-01 Assembly fixture
502 51 32-01 Assembly sleeve
502 51 34-02 Feeler gauge
English 19
Eng, p 2-39 19 96-09-13, 09.48

SERVICE DATA
Saws 36 and 41

10 6
15
Character key
Numbers by components that are bolted
refer to the tightening torque in Nm.
= Lubricate using two-stroke oil.
= Lubricate using saw chain oil.
= Lubricate using grease.
= Locking fluid (Loctite).
20 English
Eng, p 2-39 20 96-09-13, 09.48

SERVICE DATA
15
28
English 21
Eng, p 2-39 21 96-09-13, 09.48

SERVICE DATA
Saws 42, 242 and 246
5
8-10
7-8
242
4-5
15
42 246
10 5

242
42 246
Character key 3

22 English
Eng, p 2-39 22 96-09-13, 09.49

SERVICE DATA
9 20
13
28
6 9
2
English 23
Eng, p 2-39 23 96-09-13, 09.49

SERVICE DATA
Saws 40 and 45
3-4
2-3
7-8
25-35

2-3

2-3
2-3
Character key
10-12
24 English
Eng, p 2-39 24 96-09-13, 09.49

SERVICE DATA
2-3
3-4
2-3
2-3
20
2-3
2-3
8-10 2-3
2-3
3-4 2-3
25-30
2-3
English 25
Eng, p 2-39 25 96-09-13, 09.49

SERVICE DATA

Saws 51 and 55
4-5
7-8
15
30-40
6-8
3-4
3-4

8-10 1,5-2
Character key 3-4


26 English
Eng, p 2-39 26 96-09-13, 09.50

SERVICE DATA
3-4
3-4
3-4
15
8-10
12-14
3-5
1-2
25
3-4
3-4 English 27
Eng, p 2-39 27 96-09-13, 09.50

SERVICE DATA

Saws 254 and 257
5 254
10 5
257
5
10
15
35 4

3
Character key

refer to the tightening torque in Nm. 5
= Locking fluid (Loctite). 3
28 English
Eng, p 2-39 28 96-09-13, 09.50

SERVICE DATA
3
4
20
10
13
254
4 3
9
28
English 29
Eng, p 2-39 29 96-09-13, 09.54

SERVICE DATA
Saw 262
6
10
15
4
35
Character key 4
refer to the tightening torque in Nm. 4
30 English
Eng, p 2-39 30 96-09-13, 09.54

SERVICE DATA
9 20
13
4
4
3
4
9
28
5
English 31
Eng, p 2-39 31 96-09-13, 09.54

SERVICE DATA
Saws 61, 268 and 272
2
5
10
6
6
15 10
35
61
35
268 272
1
4
8
Character key
Numbers by components that are
bolted refer to the tightening torque in Nm.
3
32 English
Eng, p 2-39 32 96-09-13, 09.55

SERVICE DATA
3
1
3
61
1
3
1
15
3
10
268 272
14
5
4
6
6
4
272
4 3
3
28
9
4
English 33
Eng, p 2-39 33 96-09-13, 09.56

SERVICE DATA
Saws 281 and 288
13
4
6
15

35
Character key

34 English
Eng, p 2-39 34 96-09-13, 09.56

SERVICE DATA
4
3
6
20
11
17
3 7
6
3 4
35
7 9
English 35
Eng, p 2-39 35 96-09-13, 09.57

SERVICE DATA

Saw 394
10-12
15
6-8
2-4

7-9
Character key
Numbers by components that are
bolted refer to the tightening torque
in Nm.
36 English
Eng, p 2-39 36 96-09-13, 09.57

SERVICE DATA
5-6
20-22,5
10-12

3-5
12-14
6
3-5
5-6
4-5
30-40
2-3
English 37
Eng, p 2-39 37 96-09-13, 09.57

SERVICE DATA
Saw 3120
5
4
12
15
38
1

8
7

5
Character key
8

38 English
Eng, p 2-39 38 96-09-13, 09.57

SERVICE DATA
20 5
12
17
10
12
8

6
3
40 4
English 39
Eng, p 2-39 39 96-09-13, 09.58

TROUBLE SHOOTING
Trouble shooting schematic
Faults that can develop on the chain saw are
divided into four groups as follows. In each cat-
egory, possible malfunctions are shown on the left,
with a list of possible faults on the right. The most
probable fault is given first and so on.
Starting Idling (low rpm) (cont.)

Difficult starting Adjust L-screw Idles when L-screw Worn needle valve/needle
Air filter blocked closed Leaking control diaphragm/
Choke not working correctly cover plate
Worn choke shaft Control system sticking
Worn choke plate Worn throttle lever
Fuel filter blocked Faulty diffuser jet
Fuel line blocked
Piston ring seized Idling uneven Fuel filter blocked
Blocked impulse channel Fuel line blocked
Leaking manifold
Carburettor Loose or faulty fuel pipe Loose carburettor mounting
leaking fuel Hole in diaphragm Worn throttle valve shaft
Worn needle valve/needle Loose throttle valve screw
Control system sticking Worn throttle valve
Control system set too high Control system sticking
Leak in control system (air or Leak in throttle system (air or
fuel) fuel)
Loose cover on carburettor Control diaphragm centre knob
pump side is worn
Hole in diaphragm
Flooding when Worn needle valve Leaking control diaphragm/
the engine is not Control system set too high cover plate
running Control system sticking Crankcase leaking
L-screw requires Fuel line blocked

Idling (low rpm) constant adjustment Control system set too high
Control system sticking
Will not idle Adjust L-screw Control system (air or fuel)
Leaking manifold (intermediate) Leaking control diaphragm/
Loose carburettor mounting cover plate
Loose or faulty fuel pipe Faulty diffuser jet
Fuel filter blocked Crankcase leaking
Fuel line blocked
Fuel tank breather blocked Control system set too high
Throttle shaft and lever stiff Too much fuel at idling Control system sticking
Throttle cable sticking Control system damaged
Defective throttle return spring Worn needle valve
Bent throttle lever shaft stop Leaking control diaphragm/
Faulty diffuser jet cover plate
Control system incorrectly
assembled
Idling too rich Adjust L-screw
Worn needle valve/needle
Control system set too high
Worn throttle lever
Leaking control diaphragm/
cover plate
Control system sticking
40 English
Eng, p 40-82 40 96-09-13, 10.14

TROUBLE SHOOTING
High rpm Acceleration and retardation
Will not run at full Adjust H-screw Does not accelerate Adjust L-screw
throttle Blocked air filter Adjust H-screw
Blocked fuel tankbreather Blocked air filter
Blocked fuel filter Blocked fuel tankbreather
Fuel line blocked Blocked fuel filter
Loose or damaged fuel line Fuel line blocked
Impulse channel leaking Loose or damaged fuel line
Impulse channel blocked Impulse channel blocked
Loose cover on carburettor Loose cover on carburettor
pump side pump side
Faulty pump diaphragm Faulty pump diaphragm
Leaking manifold Leaking manifold
Loose carburettor mounting Loose carburettor mounting
Control system set too low Throttle set too low
Control system damaged Control system incorrectly
Control system incorrectly assembled
assembled Control system sticking
Leaking control diaphragm/cover Faulty diffuser jet
Control system sticking Blocked silencer
Blocked silencer
Motor stalls when Adjust L-screw
Low power Adjust H-screw throttle released Adjust H-screw
Blocked fuel tankbreather Faulty pump diaphragm
Blocked fuel filter Control system set too high
Impulse channel leaking Control system sticking
Impulse channel blocked Faulty diffuser jet
Loose cover on carburettor
pump side Over rich accelera- Adjust L-screw
Faulty pump diaphragm tion Adjust H-screw
Blocked air filter Blocked air filter
Control system sticking Faulty pump diaphragm
Leak in throttle system (air or Faulty diffuser jet
fuel)
Control system incorrectly
assembled
Loose diaphragm
Hole in diaphragm
Leaking control diaphragm/cover Trouble shooting methods
Blocked fuel tank breather
Blocked fuel filter In addition to faults given in the above schematic,
trouble shooting can be carried out on a specific
Will not Fuel line blocked component or sub-system of the chain saw. The
four-stroke Loose or damaged fuel line different testing procedures are described in
Impulse channel leaking respective sections and are as follows:
Impulse channel blocked
Loose cover on carburettor 1. Pressure testing the carburettor.
pump side See page 100.
Faulty pump diaphragm
Leaking manifold 2. Pressure testing the crankcase and cylinder.
Loose carburettor mounting See page 114.
bolts
Control system set too low 3. Pressure testing the decompression valve.
Leak in throttle system (air or See page 114.
fuel)
Control system incorrectly 4. Checking the operation of the chain brake.
assembled See page 47.
Loose diaphragm
Hole in diaphragm
Leaking control diaphragm/cover
English 41
Eng, p 40-82 41 96-09-13, 10.14

SAFETY EQUIPMENT
Chain brake
A
Dismantling
Dismantle the clutch cover and clean. See

the operating instructions.
Slide the hand guard forwards so that the

brake is actuated.
Loosen the screw on the hand guard and

screw back 2 turns.
Gently hit the screw so that the threaded part
of the bushing can be removed.
Dismantle the other part of the bushing by
means of a punch.
Remove the cylindrical pin A.
All saws except 3120 3120
Remove the cover on the chain brake spring.

The cover has 4 or 5 screws. ! WARNING!
If the clutch cover slides out of
the vice's grip the spring can fly
out with immense force resulting
in personal injury!
Wear protective glasses!
Place the clutch cover in a vice with the jaws

positioned as shown below and release the
tubular pin B.
Carefully knock out the tubular pin B.
B
! WARNING!
If the brake is not 'on', the spring
can fly out resulting in personal
injury.
Continues on next page. 3120 continues on next page.
42 English
Eng, p 40-82 42 96-09-13, 10.14

SAFETY EQUIPMENT
Slide up the back edge of the

spring with a screwdriver.
Carefully unscrew the vice so that the pres-

sure rod and the ratchet move out of the
clutch cover.
Dismantle the pressure rod from the brake

band.
Use a punch to knock out the pin holding the

knee link.
Remove the screw that holds the fixed end of

the band.
36, 41, 61, 268, 40, 42, 45, 51,

272, 281 and 288 242, 246, 55, 254,
257, 262 and 394
Lift up the band's fixed end using a screw- Knock out the band's fixed end using a
driver and remove the loose parts. punch through the hole in the clutch cover
and remove the loose parts.
English 43
Eng, p 40-82 43 96-09-13, 10.14

SAFETY EQUIPMENT
Cleaning and Inspection
Clean and inspect all parts.

The thickness of the brake band must not be
under 0.8 mm at any point.
Min. 0.8 mm
Assembly
Fit the band's fixed end into position on the

clutch cover.
Grease the knee link and knock in the tubular Fit the screw that holds the band's fixed end.
pin that holds the knee link.
Continues on next page. 3120 continues on next page.
44 English
Eng, p 40-82 44 96-09-13, 10.14

SAFETY EQUIPMENT
Slide the spring over the knee link's stud and Fit the spring and screw onto the pressure
press down the opposite end of the spring into rod on the brake band.
its recess. Note! Plastic sleeve.
Bottom the screw onto the pressure rod
thread and back off 4-5 turns.
Fit the cover over the spring.

! WARNING!
If the clutch cover slides out of
the vice's grip the spring can fly
out with immense force resulting
in personal injury!
Grease and fit the ratchet. Set the unit in a

vice, positioned in the jaws as shown below.
Continues on next page.
3120 continues on next page.
English 45
Eng, p 40-82 45 96-09-13, 10.14

SAFETY EQUIPMENT
Carefully tighten the vice until the hole for the

tubular pin and the ratchet align.
Fit the hand guard, the two bushings and the

screw.
Carefully knock in the pin.
Fit the cylindrical pin.
Pull back the hand guard so that the brake is Check the chain brake as described on the
not actuated. next page.
46 English
Eng, p 40-82 46 96-09-13, 10.15

SAFETY EQUIPMENT
Checking brake operation
! WARNING!
After repair, the chain brake
must be checked as set out in
the following instructions.
The engine should not be running

during the test.
Test that the chain brake comes on as
follows:
Hold the chain saw above a firm surface.

The distance between the bar and the
surface are shown in the table below.
L
Bar length, L Height, H
15-20 inches 50 cm
21-28 inches 70 cm
29-32 inches 80 cm
Release the front handle and let the chain

saw rotate around the rear handle.
When the bar nose hits the surface the

chain brake should trip.
English 47
Eng, p 40-82 47 96-09-13, 10.15

SAFETY EQUIPMENT
Chain catcher
Description
The chain catcher is intented to catch the

chain if it should break.
The chain catcher has a different design and
is secured differently on the chain saws
described in this manual.
The following designs are used:

Aluminium angle.
Plastic angle.
Fixed roller.
Rotating roller.
The following securing methods are used:

Using screws on the crankcase.
Using screws on the spike.
Using nuts on the spike.
Replacing
Dismantle the chain and bar. See the oper-

ating instructions
Check the chain catcher and replace if bro-

ken or badly damaged.
The tightening torque is stated in the service
data
Reassemble the chain and bar. See the

operating instructions
48 English
Eng, p 40-82 48 96-09-13, 10.15

SAFETY EQUIPMENT
Muffler
Dismantling B
! WARNING!
Do not touch the muffler until it
has cooled. Risk of burns!
C
If the saw is equipped with muffler mounting
(A), unscrew this from the crankcase and
muffler.
A
Unscrew the muffler from the cylinder

(M5 or M6 bolts, M5 or M6 nuts).
Remove the muffler, gasket and cooling plate

(B) if the saw is so equipped.
If the saw is equipped with a spark arrester

(C), remove this.
Saw 242 Cat Saws 36 and 41
Dismantle the muffler

as shown in the figure
to the right.
1
! WARNING!
The coating on and in the catalytic
converter element (A) is hazardous
to your health if touched. Wear
A
protective gloves when working on

a catalytic converter
Dismantle the muffler as shown

in the figure to the right.
English 49
Eng, p 40-82 49 96-09-13, 10.15

SAFETY EQUIPMENT
! WARNING!
The coating on and in the catalytic
converter element (A) is hazardous
to your health if touched. Wear
protective gloves when working on
Clean all parts and check the following:
That the muffler and muffler mountings are
not cracked or otherwise damaged.
That the gaskets are OK.
a catalytic converter
Assembly
Assemble the muffler and fit to the
cylinder. Tightening torque, see page
Clean all contact surfaces. Saws 36 and 41 20.
Other saws
If the saw is equipped with a spark arrester

(C), fit this.
WARNING!
Fit the cooling plate (B) if

! The coating on and in the cata-
lytic converter element (A) is
hazardous to your health if
touched. Wear protective gloves
fitted, gasket and muffler on when working on a catalytic
242 Cat converter
the cylinder.
Other saws
1 Only specially treated bolts may be used on
the catalytic converter (high temperature).
See spare parts catalogue.
See "Service data" regarding tightening torques.
1. Secure the muffler on the cylinder using the two
bolts (D).
Tighten all bolts using the tightening 2. Assemble the muffler components using the four
torque set out in the "Service data". bolts (E).
3. Secure the muffler to the crankcase using the two
B bolts (F) and Loctite.
D
C
E
A
50 English
Eng, p 40-82 50 96-09-13, 10.16

SAFETY EQUIPMENT
Stop switch
A
Dismantling
Remove the earth screw (A) and cable (B).
Press the switch's securing tabs (C) towards

each other and push out the switch.
B C
Clean the switch and check its resistance as

follows:
Connect an ohm meter as shown in the fig.

The resistance should be:
In the stop position less than 0.1 ohm.
In the run position more than 1000 ohm.
Assembly
Press the switch into the socket on the tank unit.
Fit the earth screw (A) and cable (B).
Note! On some models the earth cable should

be connected to the earth screw.
English 51
Eng, p 40-82 51 96-09-13, 10.16

SAFETY EQUIPMENT
Throttle lock
Dismantling
Saws 40, 45. Other saws. ! WARNING!

The fuel used in the chain saw
poses the following hazards:
1. The liquid and its vapours
are poisonous.
2. Can cause skin irritation.
3. Is highly inflammable.
See continuation on next page.

Remove the tank unit from the engine
assembly. See page 103.
Dismantle the throttle lock pin (A) Saws 61, 268, 268K, Saw 3120.
using a punch. 272XP, 272K, 272S, See continuation on next
A 281XP, 288XP and page.
394.
Saws 36, 41, 42, 55,

242XP, 246, 51,
Saw 394 Saws 61, 268, 272XP, 272K, 254XP, 257 and
272S, 281XP and 288XP. 262XP.
Turn the throttle lock as Slide the throttle lock and Carefully prise up the lock
shown in the figure, and lift remove it forwards as from the slot and remove.
it out with the spring from shown in the figure.
the cut-out in the handle.
52 English
Eng, p 40-82 52 96-09-13, 10.16

SAFETY EQUIPMENT
Saws 61, 268, 268K, 272XP, 272K, 272S, Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP,
281XP, 288XP and 394. 257 and 262XP.
Remove the rubber element (A). Slide out

Dismantle the throttle pin (B) by using a the throttle pin (B) and lift out the throttle arm
punch. and spring.
B B A
Saw 3120
Dismantle the throttle. On saw 394, also
remove the throttle cable.
Remove the three pins with a punch.
Saws 40 and 45
Remove the three screws in the side of the

handle as well as the screw holding the
spring under the handle.
Press the throttle lock down and move

it and the trigger forwards until the
back edge of the lock appears.
Lift out the throttle lock and the throttle.
Lift out the trigger lock.
Lift out the throttle with cable from

the front.
Remove the springs where appropriate.
English 53
Eng, p 40-82 53 96-09-13, 10.16

SAFETY EQUIPMENT
Cleaning and inspection
Clean all parts.
Check that the lock's activation

mechanism is not worn. For examples of
the activation mechanism, see the figure.
Check that the springs, where fitted, are

OK and have the correct tension.
On those saws fitted with a throttle cable, check

that the cable and lever are OK and run freely.
54 English
Eng, p 40-82 54 96-09-13, 10.17

SAFETY EQUIPMENT
Assembly
!
Saws 36, 40, 41, 45, 42,
WARNING!
242XP, 246, 51, 55, Other saws. The fuel used in the chain saw
254XP, 257 and 262XP. poses the following hazards:
1. The liquid and its vapours
are poisonous.
Fit springs in appropriate cases.
Saws 61, 268, 268K,

Saws 36, 41, 42, 242XP, Saws 40, 45. Saw 3120.
272XP, 272K, 272S,
246, 51, 55, 254XP, 257,
281XP and 288XP.
262XP and 394.
See next page.
On saw 394, fit the cable Fit the cable to the trigger Fit the trigger with the cable
to the trigger. Insert them and install the throttle lock from the front.
into the handle from the and trigger.
front.
Fit the pin (B) and spring Fit the side of the handle Fit the spring and slide the
(when used). using three screws on the throttle lock forwards from
side and one underneath, above so that its rear edge
which holds the spring. can be slid in under the edge
of the handle.
B
All saws except 40 and 45 continue on the next page.
English 55
Eng, p 40-82 55 96-09-13, 10.17

SAFETY EQUIPMENT
Saws 36, 41, 42, 242XP, Saws 61, 268, 268K,

272XP, 272K, 272S, Saw 3120.
246, 51, 55, 254XP, 257,
262XP and 394. 281XP and 288XP.
Fit the throttle lock and Fit the throttle arm and Fit the three pins that hold
spring. On saw 394, twist spring. Fit the pin and the the cable bracket, throttle
as shown in the figure two rubber dampers. lock and trigger.
when fitting.
Fit the throttle lock from the

front.
Fit the throttle lock pin.
Fit the tank unit. See page 105.
56 English
Eng, p 40-82 56 96-09-13, 10.17

STARTER
Dismantling
Dismantle the starter

See the operating instructions.
Pull out the cord 20-30 cm andinsert it into

the cut-out in the starter pulley rim.
Some saws have several long cut-outs.
Rotate the starter pulley anticlockwise until

the spring-tension on the starter pulley ceases.
Dismantle the starter pulley's centre bolt and

washer.
!
WARNING!
If the spring tension is released
when lifting the starter pulley, the
spring can fly out and cause per-
sonal injury!
Lift out the starter pulley carefully.
If the starter has a cord guide (A), remove

this
If the cord is to be replaced, cut it off and pull

out the bits from the handle and starter pulley
using a pair of long nosed pliers.
! WARNING!
Ensure that the spring does not
fly out and cause personal injury!
A
If the spring is to be replaced, remove the old

spring from the starter pulley. Some saws
have a protective plate over the spring.
English 57
Eng, p 40-82 57 96-09-13, 10.21

STARTER
Cleaning and Inspection Clean all parts and check the following:
! WARNING!
The starter cord.
The dogs in the starter pulley.
That the pawls on the flywheel are OK, and

spring back towards the centre and move freely.
Changing the ferrule
Remove the parts of the old ferrule.
Fit the new ferrule in the starter housing.
Use a wrench, spacer (A) and ball (B).

Splay out the ferrule on the inside as
shown in the figure.
58 English
Eng, p 40-82 58 96-09-13, 10.21

STARTER
Assembly
! WARNING!
If a new spring is to be fitted, position in its

security/holder so that the eye is over the
stud in the starter cover.
Slide in the spring and remove the security/

holder.
If a new cord is to be fitted, put the free end in the hole on the starter pulley. Grip the end using long
nosed pliers and pull the cord through.
42, 242, 246, 51, 55, 254,

36 and 41. 61, 268, 272, 281 and 288.
257,262, 394 and 3120.
Screw the cord to the starter Secure the cord on the Knot the cord on the starter
pulley. starter pulley. pulley.
English 59
Eng, p 40-82 59 96-09-13, 10.21

STARTER
Grease the return spring and starter pulley

bearing.
If the starter unit has a cover plate (B) over B

the spring, fit the plate.
Fit the starter pulley. Rotate back and forth

until the starter pulley catches in the spring.
Fit the starter pulley washer and bolt and

tighten the bolt to 4 Nm.
If the starter has a cord guide (A), fit this.
Pull out the cord through the hole in the cover

and fit the handle, secure with a double knot.
A
Pull out the cord 20-30 cm and insert it into
the cut-out on the starter pulley rim. Some
saws have several long cut-outs.
Rotate the starter pulley clockwise until the

cord is correctly tensioned.
Check the cord tension
A. Pull out the cord completely and hold the
pulley with your thumb.
B. In this position it should be possible to turn
the starter pulley a further 1/2 - 3/4 turn.
Fit the starter on the crankcase. Tighten the

bolts to 4 Nm.
60 English
Eng, p 40-82 60 96-09-13, 10.21

ELECTRICAL SYSTEM
Ignition system
In the event of a fault in the ignition system
the ignition module should be checked before
dismantling the ignition system.
Check the ignition module as follows:
Connect test spark plug 502 71 13-01 to the

HT lead and clamp the test spark plug to the
cylinder.
Turn the engine over using the starter.
If the test spark plug sparks the ignition

module is OK.
Dismantling
Remove the cylinder cover and the starter unit.
Remove the spark plug and fit the piston stop.
Saws 36 and 41.

Loosen the cable that runs to the stop
switch from the ignition module.
Release the cables from the guide rail and

remove the guide rail. Loosen the flywheel nut and unscrew it 1
turn
Tap the nut quickly with a hammer so that

the flywheel comes loose
Remove the nut and flywheel.
Other saws, see next page.
English 61
Eng, p 40-82 61 96-09-13, 10.21

ELECTRICAL SYSTEM
All saws except 36 and 41.
Unscrew the two pawls and springs

located on the flywheel.
Fit puller 502 51 49-02 and loosen the

flywheel.
Remove the puller, nut and flywheel.
Loosen the flywheel nut and undo until it

aligns with the end of the shaft.
Continuation all saws
The generator can be unscrewed if the saw is

Remove the ignition coil.
fitted with a handle heating system.
Remove all parts so that the cable can be
released. See applicable sections.
62 English
Eng, p 40-82 62 96-09-13, 10.22

ELECTRICAL SYSTEM
Clean all parts, especially the flywheel and
shaft taper.
Check that the flywheel is not cracked or
damaged in any other way.
Assembly
Fit the generator if the saw is fitted with
handle heating.
Tighten the bolts to 4 Nm and lock using
Loctite.
Fit the cable to the actual contact on the
saw. Adjust the length of the cable by
knotting it.
Place the flywheel on the crankshaft. Rotate

gently until the flywheel's key mates in the
keyway on the shaft
Replace the flywheel washer and nut.

Tightening torque, see "Service data".
Remove the piston stop.
Fit the ignition module

without tightening the
screws.
Turn the flywheel so that its
magnet is beside the
ignition module. Continue
assembly on
next page.
English 63
Eng, p 40-82 63 96-09-13, 10.22

ELECTRICAL SYSTEM
Insert feeler gauge 502 51 34-02

(0.3 mm) between the ignition module
and the flywheel's magnet.
Push the ignition module towards the
flywheel and tighten the bolts to 4 Nm.
Fit the guide rail, insert the cables and fit

the cable to the ignition module.
Saws 42, 242, 246, 281 and 288. Other saws.
Fit the ignition coil, which is located next to Fit the starter and cylinder cover.
the carburettor and connect the cables.
Fit the starter and cylinder cover.
Fitting the spark plug cover
Make a hole in the HT cable using pliers

502 50 06-01.
Push the HT cable through the spark plug

cover and fit the contact spring using the
pliers.
Slide the spark plug cover over the contact

spring.
Stop switch
The stop switch is described in the section

"Safety equipment". See page 51.
64 English
Eng, p 40-82 64 96-09-13, 10.23

ELECTRICAL SYSTEM
Handle heating
Description
Some saws are equipped with an electric

handle heating. This consists of the following
parts:
Generator.
Power switch.
Heater loop in the tank unit.
Handle loop with heater loop.
B
(One or two loops).
The above components are connected in
series, which means that if there is a fault in
one, all components stop working.
The wiring diagram is shown in the figure to
the right. The order of components can vary
from saw to saw.
E
Trouble shooting
A1
Trouble shooting can take place with most
components connected to the saw. An
A2
ohm meter is required for trouble shooting.
Measurement points:
A1 and A2 Earth. E.g. the cylinder
A1 - B Measurement of the generator
B-C Measurement of the handle loop
Before trouble shooting individual C-D Measurement of the heater loops
components remove the power switch and in the rear handle
disconnect one of the switch's cables. D - A2 Measurement of the power switch
Remove other components as necessary.
E.g. the cylinder cover. See the operating
instructions.
Trouble shooting individual components, see

next page.
English 65
Eng, p 40-82 65 96-09-13, 10.23

ELECTRICAL SYSTEM
Checking the generator Check the handle loop
Connect the ohm meter to the cylinder Connect the ohm meter to points B and C.
(point A1) and point B. The ohm meter The ohm meter should read 3-4 ohm.
should read 0.9-1.3 ohm. Replace the handle loop that has a higher
Replace a generator that has higher or value.
lower values.
A1
Checking the heat loops in the rear handles Checking the power switch
Connect the ohm meter to points C and D. Connect the ohm meter across the switch.
The ohm meter should read 0.7-2.5 ohm. The ohm meter should read more than
Replace a heat loops that has higher 1000 ohm with the switch in position "0".
values. The ohm meter should read, at the highest,
0.1 ohm with the switch in position "1".
66 English
Eng, p 40-82 66 96-09-13, 10.25

CENTRIFUGAL CLUTCH
Dismantling
Remove the bar and chain. See the operat-
ing instructions.
On 268K and 272K, remove the cutting
attachment. See the operating instructions.
On 272S, remove the grinder attachment.
Remove the spark plug and insert the piston

stop.
Use a spanner and remove the clutch. On

saws 36 and 41 use the service tool no. 530
03 11-12.
Note! Left-hand thread.
Saws with three Saws with one Saws with three C-springs.
coil springs. long spring.
Prise out the spring heels

using a screwdriver. Remove
Remove the springs using a Remove the spring by first the springs from the other
screwdriver. lifting a shoe using a suitable side using circlip pliers. Then
Then remove the clutch spacer (A). remove the clutch shoes.
shoes. Then remove the clutch
shoes.
A
Remove the clutch drum and needle bearing.
English 67
Eng, p 40-82 67 96-09-13, 10.26

CENTRIFUGAL CLUTCH
Clean all parts and inspect the following:
Clutch shoes Clutch shoes

without chamfers. with chamfers.
That measurement A is not below 1 mm. That measurement B is not under 1 mm.
Check that there is no play between the

clutch shoe and clutch hub
Check for wear on the chain sprocket.
Check the condition of the needle bearing

and the bearing surface on the crankshaft.
That the clutch drum friction surface and

bearing surface are undamaged.
68 English
Eng, p 40-82 68 96-09-13, 10.26

CENTRIFUGAL CLUTCH
Assembly
Grease the needle bearing (C) and fit onto
the crankshaft. Then fit the clutch drum.
NOTE! The bearing can also be greased

later through the hole on the crankshaft.
To prevent imbalance all clutch shoes should C

be replaced at the same time.
NOTE! The clutch

springs should not be
Saws with three opened out more than
Saws with one Saws with three C-springs.
coil springs. necessary. Risk of
long spring.
deformation.
Locate the clutch shoes on Locate the clutch shoes on the Locate the clutch shoes on the
the hub and fit the springs hub. Lift a shoe using a suit- hub and fit the springs with the
with the help of pliers. able spacer (A) and fit the help of circlip pliers.
spring.
A
Using a spanner secure the clutch centre.

On saws 36 and 41 use service tool no.
530 03 11-12.
Note! Left-hand thread.
Fit the chain and bar. See the operating instruc-

Remove the piston stop and fit the spark tions. On 268K and 272K, fit the cutting attach-
plug. ment.
English 69
Eng, p 40-82 69 96-09-13, 10.26

LUBRICATION SYSTEM
Dismantling
Dismantle the following parts: Starter. See the operating instructions

Centrifugal clutch. See page 67.
Saws 36, 40, 41, 45, 51 and 55. See page 72 Saw 3120. See page 72 Other saws.
Remove the pump drive and washer.
Undo the three bolts (A) and remove the

oil pump. Some pumps have to be
removed by using extractor screws. M5
Saws 61, 268, 272XP. See next page. screws should be inserted into the 2
threaded holes in the pump body and
tightened equally to lift the pump and
thrust washer. Other pumps have a cut-out
Saws 281XP and 288 XP. See next page.
(C) for a screwdriver to prise off the pump.
Both types are shown below.
Saw 394. See page 72.
Saws 42, 242XP, 246, 254XP, 262XP and 257.
Dismantle the oil pump as follows:
1. Unscrew screw (A) and remove locking

clip (B).
D E
2. Undo screw (C).
3. Lever out the pump piston (D) and

plastic plug (E) using a screwdriver.
B
4. Remove the seal (F). A
C F
70 English
Eng, p 40-82 70 96-09-13, 10.27

LUBRICATION SYSTEM
Saws 61, 268, 272XP.
E C D
F
1. Remove the lock washer (A), washer,
spring and adjuster screw (B). B
2. Remove the locking lacquer and undo
screw (C). G
3. Knock the edge of the pump housing
against a piece of wood so that the
pump piston (D) slides out of the
housing.
4. Remove the pinion (E) with washers
and springs.
5. Remove the pin (F). A
6. Remove the seal (G).
7. If necessary remove the O-ring (H). H
Saws 281XP and 288 XP.
Dismantle the oil pump as follows: C B
1. Undo the adjuster screw (A). F

2. Remove the plug (B) with pump piston
(C) and spring with washers. A
3. Dismantle the O-ring (D). Replace if
necessary.
4. If necessary, replace the seal (E).
5. If necessary, replace the O-ring (F).
D
English 71
Eng, p 40-82 71 96-09-13, 10.27

LUBRICATION SYSTEM
Saw 394.
Dismantle the oil pump as follows: C D
1. Dismantle the screw (A) so that the

spring and latch pin (B) can be
removed.
2. Lever out the pump piston (C) with the
plastic plug (D) using a screwdriver.
3. Remove the seal (E). B

Saw 3120.
1. Undo the screws (A) and remove the parts as
shown in the figure below.
2. Undo screw (B). NOTE! Left-hand thread.
Undo the three bolts that hold

the oil pump and lift up the pump
by the cut-out for the adjuster
screw. Lift off the pump and
loosen the wire for manual oil
supply.
B A
72 English
Eng, p 40-82 72 96-09-13, 10.31

LUBRICATION SYSTEM
Saws 36, 40, 41, 45, 51 and 55.
Dismantle the chain guide plates as shown

in respective diagrams below.
36/41 40/45 51/55
Saws 36, 40, 41 and 45. Saws 51 and 55.
Undo the two bolts and lift off the pump Lift off the pump and the upper seal.
and the upper seal.
Take the pump apart as shown in the exploded view on

the next page.
English 73
Eng, p 40-82 73 96-09-13, 10.31

LUBRICATION SYSTEM
D E F G E F
B C
A
C B A
36/41 40/45
A. Lower seal.
B. Pump cylinder.
C. Upper seal.
D. Chain guide plate.
E. Pump housing.
F. Pump piston.
D E F G G. Worm gear.
C B A
50/51
74 English
Eng, p 40-82 74 96-09-13, 10.31

LUBRICATION SYSTEM
Dismantling the oil pump's
worm gear
On some saws the worm gear for the oil

pump is pressed on the crankshaft.
Remove the worm gear by using the

service tool for the saw in question. See
"Tools".
First screw the tool onto the entire worm

gear
Turn the screw until the worm gear is
removed.
English 75
Eng, p 40-82 75 96-09-13, 10.31

LUBRICATION SYSTEM
Clean all parts and check the following

when appropriate to the saw in question.
That the taper on the adjuster screw

shows no signs of wear.
That the pump piston's eccentric face does

not show signs of wear.
That the pump piston's pinion gear is undamaged.
That the worm gear on the oil pump drive

is undamaged.
That all seals are undamaged.
The oil pipe is not blocked and the filter

screen is clean.
76 English
Eng, p 40-82 76 96-09-13, 10.32

LUBRICATION SYSTEM
Assembling the worm gear
On those saws where the oil pump worm Screw the worm gear into the dismantling
gear is pressed on the crankshaft. tool and press the worm gear onto the
crankshaft until it bottoms against the
collar.
Assembling the oil pump
Saws 42, 242XP, 246, 254XP, 262XP and 257.
Fit the oil pump as follows:
1. Apply SAE 30 oil to all moving parts.

2. Insert the pump piston (D) with
washers and spring. D E
3. Press in the pump piston a little more
and screw in the adjuster screw (C).
4. Insert the plastic plug (E).
5. Refit screw (A) and locking clip (B).
6. Fit the seal (F). B
A
C F
Saws 61, 268, 272XP. See continuation, page 80.
Fit the oil pump as follows: E C D

F
2. Fit the seal (G) if necessary. B
3. Press in pin (F).
4. Locate the pinion (E) with washers and G I
spring.
5. Insert the pump piston (D) through the
pinion, spring and washers in the pump
housing.
6. Fit screw (C). The screw should be
locked using Loctite or locking lacquer.
7. Fit the adjuster screw (I) with washers, A
spring and locking clip (A).
8. Fit the O-ring (H). H
See continuation, page 80.
English 77
Eng, p 40-82 77 96-09-13, 10.33

LUBRICATION SYSTEM
Saws 281XP and 288 XP.
Fit the oil pump as follows: C B

1. Apply SAE 30 oil to all moving parts F
2. Fit the seal (E) if necessary.
3. Fit the plug (B) and spring with washers A
on the pump piston (C) and fit the unit
in the pump housing.
4. Fit the adjuster screw (A) in the pump
housing, and through the hole in plug
(B). D
5. Fit the O-rings (D) and (F).
E
Saw 394. See continuation, page 80.

C D
2. Fit the pump piston (C) with washers
and spring in the pump housing.
3. Fit the latch pin (B), press in the pump
piston (C) a little more and fit the
adjuster screw (A).
B
4. Fit the seal (E).
5. Fit the plug (D).
See continuation, page 80.
78 English
Eng, p 40-82 78 96-09-13, 10.33

LUBRICATION SYSTEM
Saw 3120.
1. Apply SAE 30 oil to all moving parts 5. Fit lever arm (F).
2. Fit the seal (C). 6. Fit units (B-F-G) with spring (H) and
3. Fit the pump piston (D) with spring. screw in position using screws (A) and
Press in the piston and hold it in latch (J).
position with a screwdriver from the 7. Remove the screwdriver.
pump housing's inside in slot (E). 8. Fit a new O-rings (K) and (L).
4. Fit screw (B) so that it is positioned
approx. one turn from the bottom.
NOTE! Left-hand thread
F D E
H
G
J
C K
B A
Fit the wire for manual oil supply. See continuation on next page.
English 79
Eng, p 40-82 79 96-09-13, 10.33

LUBRICATION SYSTEM
Saws 42, 61, 242, 246, 254, 257, 262, 268, 272, 281, 288, 394 and 3120.
Saws 61, 268, 272, 281 and 288
Use the tapered sleeve which

is placed on the shaft when
fitting the oil pump. Otherwise
the seals will be damaged.
1. Lubricate the pinion gear with grease.
2. Fit the oil pump on the saw by

tightening the three bolts.
3. If the tapered sleeve has been used,

remove it.
4. Fit the centrifugal clutch.

See page 69.
5. Fit the bar and chain.
6. Adjust the oil pump for the correct oil flow.

80 English
Eng, p 40-82 80 96-09-13, 10.34

LUBRICATION SYSTEM
Saws 36, 40, 41, 45, 51 and 55.
1. Apply SAE 30 oil to all moving parts. A. Lower seal.

2. Fit the worm gear (G) on the B. Pump cylinder.
crankshaft, if necessary C. Upper seal.
3. Fit the pump piston (F) in the pump D. Chain guide plate.
cylinder (B). E. Pump housing.
4. Fill the pump recess with grease. F. Pump piston.
5. Fit the unit in the pump housing (E). G. Worm gear
Ensure the pump cylinder's cut-out
aligns in the pump housing.
6. Fit the lower seal (A) on the crankcase.
D E F G E F
B C
A
C B A
36/41 40/45
D E F G
C B A
50/51
Saws 36, 40, 41 and 45, see Saws 51 and 55, see continuation
continuation on the next page. on the next page.
English 81
Eng, p 40-82 81 96-09-13, 10.34

LUBRICATION SYSTEM
Saws 36, 40, 41 and 45. Saws 51 and 55.
Fit the oil pump in the crankcase, tighten Fit the oil pump in the crankcase and fit
the two bolts and fit the upper seal. the upper seal.
Fit the chain guide plates according to

respective diagrams below.
36/41 40/45 51/55
Fit the bar and chain.
82 English
Eng, p 40-82 82 96-09-13, 10.34

CARBURETTOR
Description
!
The diagrams in this description do not
WARNING!
correspond with the carburettor fitted on The fuel used in the chain saw poses
the chain saws. They serve only to show the following hazards:
the principles of design and operation. 1. The liquid and its vapours are
poisonous.
Design
The carburettor consists of three sub-systems:
Metering unit, A.
Mixing venturi, B.
Pump unit, C.
The metering unit (A) contains the jets and

fuel control functions. It is here the correct
amount of fuel for the given engine speed
and power is metered.
The mixing venturi (B) houses the choke,

throttle valve and diffuser jets. Here air is
mixed with the fuel to give a fuel/air
mixture that can be ignited by the ignition
spark.
In the pump unit (C), fuel is pumped from the

fuel tank to the metering unit. One side of the
pump diaphragm is connected to the crankcase
and pulses in time with the pressure changes in
the crankcase. The other side of the diaphragm
pumps the fuel.
English 83
Eng, p 83-124 83 96-09-13, 11.08

CARBURETTOR
Operation
The carburettor operates differently in the

following modes:
Cold start
Idling
Part throttle
Full throttle
In the cold start mode the choke valve (D)

is fully closed. This increases the vacuum
in the carburettor and fuel is easier to suck D E F G
from all the diffuser jets (E, F and G). The
throttle valve (H) is partly open.
In the idling mode (H) the throttle valve is

closed. Air is sucked in through an
aperture in the throttle valve and a small
amount of fuel is supplied through the
diffuser jet (G).
H G
In the part throttle mode the throttle valve

(H) is partially open. Fuel is supplied
through the diffuser jets (F and G).
H F G
In the full throttle mode both valves are

open and fuel is supplied through all three
diffuser jets (E, F and G).
E F G
84 English
Eng, p 83-124 84 96-09-13, 11.08

CARBURETTOR
Dismantling
! WARNING!
1. The liquid and its vapours are
poisonous.
Dismantle all parts necessary and remove

the carburettor from the saw. On some
models the cylinder needs to be loosened
and lifted to be able to remove the
carburettor.
See the carburettor in question on the next

four pages and the instructions below. Semi fixed jet/fixed jet
Plugs Some carburettors have an extra jet (semi

fixed jet). The jet is of brass and is located
in the metering unit and is used to give a
When cleaning the carburettor the plugs
fuel supplement. On average 10% of the
must be removed. Remove as follows:
fuel passes through the jet.
Below or next to the jet is a screen which
1. Drill a hole in the plug.
needs to be cleaned.
2. Insert a screwdriver or punch in the hole
Dismantle the jet and/or screen in one of
and prise up the plug.
the following ways:
1. Knock the unit into the venturi using a

punch and take the unit apart. (some
Tillotson models).
2. Dismantle the lock washer over the jet

and lift off the jet and screen.
English 85
Eng, p 83-124 85 96-09-13, 11.09

CARBURETTOR
Tillotson HS 228 B E
1. Remove the cover (A) over the metering
unit and carefully remove the control F
diaphragm (B) with the gasket.
G
2. Undo the screw (H) and take out
the needle valve (C) with lever arm, D
shaft and spring.
3. Remove the cover (E) over the pump unit

and carefully remove the gasket (F) and
the pump diaphragm (G).
4. Using a needle or the like carefully remove J

the fuel screen (D).
C
5. Unscrew the high and low speed jet
H
screws.
6. Remove the plugs (J). B

See page 85.
A
7. If necessary remove the throttle and choke
valves as well as the shafts, lever arms
and springs.
Tillotson HS 255 B
1. Remove the cover (A) over the metering D E
unit and carefully remove the control
F
2. Undo the screw (H) and take out
G
the needle valve (C) with lever
arm, shaft and spring.
I
4. Using a needle or the like carefully

J
remove the fuel screen (D). H

C
screws.
H K
6. Remove the plugs (J). See page 85.
B
7. If necessary remove the throttle and
choke valves as well as the shafts, lever A
arms and springs.
8. Remove the speed governor (I). (Only

272K, 268K and 272S).
9. Remove the semi fixed jet (K). See page 85.
86 English
Eng, p 83-124 86 96-09-13, 11.09

CARBURETTOR
Tillotson HS 260 A
E
G
2. Undo the screw (H) and take out the
needle valve (C) with lever arm, shaft and D
spring.

J
4. Using a needle or the like carefully remove H
C
screws. H K
6. Remove the plugs (J). See page 85. B
A
and springs.
Walbro HDA and HD A

2. Undo the screw (H) and take out the H

needle valve (C) with lever arm, shaft and C
spring.
3. Remove the cover (E) over the pump J

unit and carefully remove the gasket (F)
and the pump diaphragm (G).
4. Using a needle or the like carefully remove

D
screws.
G
6. Remove the plug (J). See page 85.
F
valves as well as the shafts, lever arms and E
springs.
English 87
Eng, p 83-124 87 96-09-13, 11.09

CARBURETTOR
Walbro WJ
E
G
2. Undo the screw (H) and take out the D
needle valve (C) with lever arm, shaft and
spring.

J
C K
screws. H

B
7. If necessary remove the throttle and choke A
and springs.
Walbro WG A
B

H
C
spring.
K
J

5. Unscrew the low speed jet screws.
6. Remove the plugs (J). See page 85.

D
valves as well as the shafts, lever arms G
and springs.
F
E
88 English
Eng, p 83-124 88 96-09-13, 11.09

CARBURETTOR
Walbro WT
1. Remove the cover (A) over the metering E

needle valve (C) with lever arm, shaft D F
and spring.
G
3. Remove the cover (E) over the pump
unit and carefully remove the gasket (F)
and the pump diaphragm (G).
C
J
screws.

B H K
A
and springs.
8. Remove the semi fixed jet with diffuser

jet (K). See page 85.
ZAMA C1Q-EL1
A
B
H
spring.

C
K
D
G
screws.
F
6. If necessary remove the throttle and
E
choke valves as well as the shafts, lever
arms and springs.
English 89
Eng, p 83-124 89 96-09-13, 11.09

CARBURETTOR
! WARNING!
poisonous.
Clean all components in petrol. Wear

gloves or skin protection cream.
! WARNING!
Never direct the compressed air
jet towards the body. Air can be
forced into the blood stream and
can cause fatality.
Use compressed air to dry the petrol on the

components. Direct the air through all
channels in the carburettor housing and
ensure that they are not blocked.
Refer to the carburettor diagram in

question on the previous pages and check
the following:
1. That the gasket and pump and control

diaphragms are undamaged.
2. That there is no play on the throttle and

choke valve shafts.
3. That the needle valve and its lever are

not worn.
4. That the fuel screen is undamaged
5. That the tips of the high and low speed

jet screws are not damaged.
6. On Tillotson HS 255 B, that the speed

governor (I) is clean.
7. That the air intake manifold is not cracked.
90 English
Eng, p 83-124 90 96-09-13, 11.09

CARBURETTOR
Assembly
!
Refer to the carburettor in question on the WARNING!
next eight pages. A pressure test, see The fuel used in the chain saw
page 100, should be carried out after poses the following hazards:
assembling and before the carburettor is 1. The fluid and its vapours are
refitted to the saw. poisonous.
Plugs Semi fixed jet/fixed jet
When cleaning the carburettor the plugs Some carburettors have an extra jet (semi
must be removed. fixed jet). The jet is of brass and is located
Reassemble as follows: in the metering unit and is used to give a
fuel supplement. On average 10% of the
1. Place the plug in the hole with the fuel passes through the jet.
convex side facing upwards. Below or next to the jet is a screen which
needs to be cleaned.
2. Expand the plug by using a punch on
the top side. Reassemble the jet and/or screen in one
of the following ways:
1. Put together the unit and fit it in the

carburettor by means of a punch (Some
Tillotson models).
2. Fit the jet with screen and lock washer.
English 91
Eng, p 83-124 91 96-09-13, 11.10

CARBURETTOR
Tillotson HS 228 B
Maintain a high level of cleanliness when E

reassembling the carburettor. Even small
particles of dirt can cause operating F
problems.
G
1. If the throttle and choke valves, shafts,
lever arms and springs have been D
dismantled these must be reassembled.
Lubricate the shaft bearings using a
light oil.
2. Fit the plugs (J). See page 91.

J
3. Fit the high and low jet screws and
springs. NOTE! Do not tighten the C
screws against the seats. This can
damage the seats and needle tips. H
4. Fit the fuel screen (D) by using the B

handle of a small screwdriver.
A
5. Fit the pump diaphragm (G), gasket
(F) and cover (E) on the pump unit.
6. Fit the needle valve (C) with lever arm,

shaft and spring and tighten screw (H).
7. Check, using or a ruler or the like, that

the lever arm is level with the chamber
floor. See the figure to the lower right.
The lever arm can be bent if necessary
to achieve the correct settings.
8. Fit the control diaphragm (B) with

gasket and cover (A) on the metering
unit.
9. Carry out a pressure test.

See page 100.
92 English
Eng, p 83-124 92 96-09-13, 11.10

CARBURETTOR
Tillotson HS 255 B
D E
Maintain a high level of cleanliness when
particles of dirt can cause operating prob- F
lems.
G
I
lever arms and springs have been
Lubricate the shaft bearings using a light
oil.

J
H
3. Fit the semi fixed jet (K). See page 91.
C
4. Fit the high and low jet screws and springs.
NOTE! Do not tighten the screws against
H K
the seats. This can damage the seats and
needle tips. B
5. Fit the fuel screen (D) by using the handle A
of a small screwdriver.


8. Check, using or a ruler or the like, that the

lever arm is level with the chamber floor.
See the figure to the lower right. The lever
arm can be bent if necessary to achieve
the correct settings.
9. Fit the speed governor (I). Lock with

Loctite or locking lacquer. (Only applies to
272K, 268K and 272S).
10. Fit the control diaphragm (B) with gasket

and cover (A) on the metering unit.
11. Carry out a pressure test.

See page 100.
English 93
Eng, p 83-124 93 96-09-13, 11.10

CARBURETTOR
Tillotson HS 260 A
E
F
particles of dirt can cause operating
problems.
G

D
oil.
2. Fit the plugs (J). See page 91. J

H
C
4. Fit the high and low jet screws and
springs. NOTE! Do not tighten the screws H K
against the seats. This can damage the
seats and needle tips. B
5. Fit the fuel screen (D) by using the handle A





10. Carry out a pressure test. See page 100.
94 English
Eng, p 83-124 94 96-09-13, 11.11

CARBURETTOR
Walbro HDA och HD A
B
particles of dirt can cause operating prob-
lems.
1. If the throttle and choke valves, shafts, H

lever arms and springs have been C
Lubricate the shaft bearings using a
light oil. J

D
needle tips.
G
4. Fit the fuel screen (D) by using the handle
F
E



English 95
Eng, p 83-124 95 96-09-13, 11.11

CARBURETTOR
Walbro WJ
E
F
reassembling the carburettor. Even small G
particles of dirt can cause operating prob- D
lems.
1. If the throttle and choke valves, shafts, lever

arms and springs have been dismantled
these must be reassembled. Lubricate the
shaft bearings using a light oil.
J
3. Fit the semi fixed jet (K). See page 91. C K
4. Fit the high and low jet screws and springs. H

needle tips. B
A

7. Fit the needle valve (C) with lever arm, shaft

and spring and tighten screw (H).

arm can be bent if necessary to achieve the
correct settings.

96 English
Eng, p 83-124 96 96-09-13, 11.11

CARBURETTOR
Walbro WG
A
Maintain a high level of cleanliness when B

particles of dirt can cause operating prob-
lems.
H
1. If the throttle and choke valves, shafts, C
dismantled these must be reassembled. K
Lubricate the shaft bearings using a light oil.
J
3. Fit the fixed jet (K). See page 91.

needle tips.
D
of a small screwdriver. G
6. Fit the pump diaphragm (G), gasket F

E

correct settings.

English 97
Eng, p 83-124 97 96-09-13, 11.11

CARBURETTOR
Walbro WT
E

particles of dirt can cause operating F
D
problems.
G
Lubricate the shaft bearings using a light oil.
C
J

the seats. This can damage the seats and B H K
needle tips.
A
5. Fit the fuel screen (D) by using the handle of
a small screwdriver.



correct settings.

98 English
Eng, p 83-124 98 96-09-13, 11.11

CARBURETTOR
ZAMA C1Q-EL1

particles of dirt can cause operating A
problems.
B
dismantled these must be reassembled. H
oil.

NOTE! Do not tighten the screws against C
needle tips. K
3. Fit the fuel screen (D) by using the handle D

G
(F) and cover (E) on the pump unit. F
5. Fit the needle valve (C) with lever arm, E



English 99
Eng, p 83-124 99 96-09-13, 11.11

CARBURETTOR
Pressure testing
Pressure testing should be carried out with the

carburettor fully assembled. Testing should
! WARNING!
poisonous.
always be carried out after the carburettor has 2. Can cause skin irritation.
been repaired, but a test can also be made for 3. Is highly inflammable.
trouble shooting before dismantling.
Make the test as follows:
1. Set the high and low speed jet screws

one turn open from the bottom.
2. Connect pressure tester 502 50 38-01

to the carburettors fuel intake.
3. Lower the carburettor into a beaker of

water.
4. Pump up the pressure to 50 kPa (0.5

bar) and clamp the pump tube with the
spring clip.
5. There should be no leakage. If a

leakage occurs refer to the table below.
Leakage on Fault with
Diffuser jets Needle valve
Leakage on the Pump diaphragm

pulse tube
Ventilation hole Control diaphragm

above the metering unit
Refitting onto chain saw
Fit the carburettor to the chain saw and

refit any other parts removed. Carburettor adjustment. See the operating
For tightening torques, see the Service instructions for the saw in question.
data for the saw in question.
100 English
Eng, p 83-124 100 96-09-13, 11.11

AIR FILTER
Replace the chain saws air filter at the
intervals stated in respective operating in-
structions.
It is extremely important that the air filter

units on power cutters 268K, 272K and stump
grinder 272S are maintained correctly. The
air filter units on these models have there-
fore been included in this workshop manual.
268K, 272K and 272S A

The air filter system consists of:
1. Prefilter.
2. Main filter.
Prefilter
The prefilter is an oiled foam filter which is

easily accessible under the filter cover (A).
In dusty conditions this filter should be
checked/replaced after every second
refuelling.
The filter should be cleaned and oiled regu-
larly to obtain maximum filtration efficiency.
Cleaning
Dismantle the filter. Wash the filter in warm

soapy water. After cleaning, rinse the filter
thoroughly in clean water. Squeeze and let
the filter dry.
NOTE!
Compressed air at a high pressure can
damage the foam.
Oiling
Oil the filter carefully. It is extremely impor-

tant that the entire filter is saturated with oil.
Use HUSQVARNA oil no. 503 4773-01. The
bottle holds 0.1l, which is sufficient for three
applications.
English 101
Eng, p 83-124 101 96-09-13, 11.15

AIR FILTER
Main filter
The main filter is a paper filter and is accessible under the cover (B).
This filter should be replaced/cleaned when the saws power de-
creases or after 1-2 weeks. The filter is cleaned either by shaking or
carefully blowing clean with compressed air. Note. The filter must not
be washed.
102 English
Eng, p 83-124 102 96-09-13, 11.15

TANK UNIT
Dismantling
Empty the tank and dismantle the cylinder

cover as well as the bar and chain.
! WARNING!
poisonous.
Loosen the fuel pipe and disconnect the
throttle cable if fitted.
The figures on the next page illustrate all The mountings applying to the chain saw in
types of mountings between the tank unit and question is evident from the table on the next
the engine sub-assembly marked by letters. page.
If heated handles are fitted remove the con- NOTE!

nections. Take care that the fuel pipe and throttle
The cable to the switch cannot be removed cable are not damaged.
before the tank unit and the engine sub-
assembly are separated.
Dismantle the bolts as shown in the figures

and the table on the next page and lift off the
tank unit from the engine sub-assembly.
Clean all parts and check the following:
That the fuel pipe is undamaged.

That the tank unit is not cracked.
That the throttle cable runs freely.
That the AV-system is undamaged For AV-
system see page 107.
That the tank breather is not blocked or
leaks. If the fuel pipe needs to be replaced, meas-
That the fuel cap does not leak. ure its length outside of the tank unit and
That the fuel pipe bushing seals make a note of the length. This information is
That the fuel filter is not blocked. needed when fitting a new pipe.
English 103
Eng, p 83-124 103 96-09-13, 11.15

TANK UNIT
B
C
L
K
J
I
F G H
Saw Bolts placed at Saw Bolts placed at
36 A, D, F, K 257 A, D, F, L
40 Has no tank unit 262XP A, D, F, L
41 A, D, F, K 268 A, C, D, F, G, K
42 A, D (under a cover) F, G, L 268K A, C, D, F, G, K

45 Has no tank unit 272XP A, C, D, F, G, K
51 A, D, F, L (all under covers) 272K A, C, D, F, G, K
55 A, D, F, L (all under covers) 272S A, C, D, F, G, K

61 A, C, D, F, G, K 281XP A, C, D, F, G, K
242XP A, D (under a cover) F, G, L 288XP A, C, D, F, G, K
246 A, D (under a cover) F, G, L 394XP B, E, G, I, H

254XP A, D, F, L 3120XP C, D, F, I, J
104 English
Eng, p 83-124 104 96-09-13, 11.15

TANK UNIT
Assembly
If a new fuel pipe is to be fitted proceed as 3. Twist the hose so that it takes on the same
follows: angle to the carburettor and let the hose
1. Measure the length of the old hose out- protrude as much as the old hose did.
side of the tank unit, note the length.
4. Pull the hose through the filler hole using
2. Oil half of the hose lightly and thread the tool 502 50 83-01, cut off the bevelled end
oiled part into the fuel tank from the outside. and fit the fuel filter.
Fit the throttle and lock.
NOTE!
Ensure that the fuel pipe and throttle
cable are not damaged.
Fit the engine sub-assembly to the tank unit

and at the same time insert the fuel pipe in
the bottom of the carburettor space.
If the saw has a throttle cable, insert this into The figures on the previous page illustrate all
the carburettor space too. types of mountings between the tank unit and
the engine sub-assembly marked by letters.
The mountings applying to the chain saw in

Make the handle heater connections if nec- question is evident from the table on the next
essary. page.
Fit the bolts as set out in the table on the

previous page. Tightening torques, see the
service data for the saw in question.
Connect the fuel pipe and the throttle cable to

the carburettor.
Fit the cylinder cover and the chain and bar.
English 105
Eng, p 83-124 105 96-09-13, 11.15

ANTI-VIBRATION SYSTEM
Description
The anti-vibration system reduces the vibra-
tions which pass from the engine and cutting
equipment to the handles. The anti-vibration
system consists either of rubber elements or
coil springs.
The systems movement limitation consists
of side absorbers and/or stop screws.
Dismantling
The tank unit must be removed from the engine sub-assembly to access the anti-vibration system.
See the previous pages.
Saw 394 Saws 40, 45 and 3120 Other saws
Release the catch on the plastic key. Remove the rubber element using re-
spective tools as shown in the figure
below.
Slide off the spring and its holder.

Remove the spring element using an allen
key as shown below.
106 English
Eng, p 83-124 106 96-09-13, 11.15

ANTI-VIBRATION SYSTEM
Assembly
Fit the rubber stop with the help of a wire or
the like.
Fitting the anti-vibration systems side absorber.
Fitting the anti-vibration systems damper element. Tightening torques, see the Service data for
respective saws.
Saw 394 Saws 40, 45 and 3120 Other saws
Slide in the spring and its holder. Fit the rubber element using the tools
Fit the spring element using an allen key as

English 107
Eng, p 83-124 107 96-09-13, 11.15

PISTON AND CYLINDER
Dismantling
Dismantle the following parts:
Cylinder cover. See operating instructions. Carburettor.
Spark plug. See operating instructions. Muffler.
Saws 36, 40, 41 and 45. Other saws
Dismantle the insulation plate between the On saw 394, disconnect the anti-vibration
cylinder and the carburettor and the intake spring (A) from the cylinder.
manifold. On all chain saws, undo the four cylinder
bolts (B). The bolts are removed using a 4
mm allen key (smaller saws) or 3/16 allen
key (larger saws).
B A
Remove the cables to the ignition coil.

Remove the ignition coil.
NOTE!
Ensure that no dirt or other foreign
particles fall into the crankcase.
Saws 36 and 41. Saws 40 and 45.
Dismantle the tank unit. Undo the four bolts under Carefully lift up the cylinder.
See page 102. the crankcase.
Immediately cover the crankcase opening/

crankshaft and crankshaft bearing with a
paper or cloth.
Remove one of the circlips on the piston
push out the gudgeon pin and remove the
piston.
Remove the needle bearing from the little

end of the connecting rod. Remove the
decompression valve if fitted.
108 English
Eng, p 83-124 108 96-09-13, 11.16

PISTON AND CYLINDER
Clean all parts, scrape off any gasket

residue remove carbon deposits from the
following areas:
1. The piston crown.
2. The top of the cylinder bore.
3. The cylinder exhaust port.
4. The decompression valve channel.
Check the following:
1. That the cylinders surface coating is not

worn, especially the upper part of the
cylinder.
2. That the cylinder is free of score marks.
3. That the piston is free of score marks.

See Faults and causes on the next page.
Small scratches can be polished off using
fine emery paper.
4. That the piston ring is not stuck into its

groove. Max 1 mm
5. Measure the piston ring wear by placing it

in the bottom of the cylinder bore and
measuring the gap and which should not
exceed 1 mm.
6. That the needle bearing is undamaged.
7. That the intake manifold is undamaged.
Pressure test the decompression valve as

follows:
1. Connect the tool 502 50 38-01 to the

decompression valve
2. Pump up the pressure to 80 kPa (0.8 bar).
3. Wait 30 seconds.
4. The pressure should not drop below 60 kPa
(0.6 bar).
English 109
Eng, p 83-124 109 96-09-13, 11.16

PISTON AND CYLINDER
On saws 40 and 45, check the rubber sealing

on the shaft seat. Change the shaft seat, if
necessary.
Faults and causes
Score marks on the piston.
1. Incorrect carburettor setting max. speed

too high
2. Too low octane fuel.
3. Too little or incorrect oil in the fuel.
Carbon build-up
1. Incorrect carburettor setting max. speed

too low.
2. Too much or incorrect oil in the fuel.
Piston ring breakage
1. Excessive engine speed
2. Piston ring worn out.
3. Oversized piston ring groove.
110 English
Eng, p 83-124 110 96-09-13, 11.16

PISTON AND CYLINDER
Assembly
NOTE!
Ensure that no dirt or other foreign particles
fall into the crankcase.
Oil the needle bearing and fit it into the

connecting rod little end.
Refit the piston with the arrow facing the

exhaust port.
Slide in the gudgeon pin and fit the circlip.
Other saws
Saws 36, 40, 41 and 45
Fit a new cylinder gasket
Oil the piston and piston ring.

Compress the piston ring either by hand or
by using tool 502 50 70-01. Carefully fit
the cylinder.
Saws 36 and 41
Apply silicone rubber 504 98

26-01 to the lower crank-
case halfs contact surfaces.
Check that the seals fit in
their grooves correctly.
Tighten the crankcase
halves. Tightening torque
refer to Service data.
English 111
Eng, p 83-124 111 96-09-13, 12.56

PISTON AND CYLINDER
Saws 36, 40, 41 and 45. Other saws
Fit the four bolts under the crankcase.

Tightening torque, see Service data.
Saws 36 and 41. Saws 40 and 45.

Fit the four cylinder bolts (B).
On saw 394, connect the anti-vibration spring
(A) to the cylinder. The bolts are tightened
Fit the tank unit. using a 4 mm allen key (smaller saws) or
3/16 allen key (larger saws).
B A
Fit the ignition coil and its cables.
Fit the intake manifold and the insulation wall

between the cylinder and carburettor.
Fit the decompression valve.
Carry out a pressure test as set out on the next page.
Fit the following parts:

Cylinder cover. See operating instructions. Carburettor.
Spark plug. See operating instructions. Muffler.
If a new piston or cylinder has been fitted the saw must be run-in for 3-4 hours with the carburettor
set to the basic settings. See the operating instructions for the saw in question.
112 English
Eng, p 83-124 112 96-09-13, 12.57

PISTON AND CYLINDER
Pressure testing
Decompression valve
Test the decompression valve as follows.
1. Connect the tool 502 50 38-01 to the

decompression valve
2. Pump up the pressure to 80 kPa (0.8 bar).
3. Wait 30 seconds.
4. The pressure should not drop below 60 kPa
(0.6 bar).
Crankcase and cylinder
The following parts must be removed to

pressure test the crankcase and cylinder:
Carburettor.
Muffler.
Carry out the test as follows:
1. Fit the cover plates (service tool) on the

intake manifold and exhaust port.
2. Connect tool 502 50 38-01 to the cover

plate on the intake manifold.
The decompression valve should be
closed.
3. Plug the opening to the impulse

channel.
4. Pump up the pressure to 80 kPa

(0.8 bar).
5. Wait 30 seconds.
6. The pressure should not drop below

60 kPa (0.6 bar).
7. Leakage can occur from the

decompression valve and the
crankshaft seals.
Fit the following: Carburettor.

Muffler
English 113
Eng, p 83-124 113 96-09-13, 12.59

CRANKCASE AND CRANKSHAFT
This section deals with the following:
Crankcase and crankshaft (describes how the

whole assembly is dismantled and assembled).
Bar bolts (only describes replacing the bar
bolts). See page 121.
Seals. Describes changing the seals without
splitting the crankcase. See page 122.
Dismantling
Before the crankcase can be split the follow- D. Centrifugal clutch. See page 67.
ing must be removed: E. Oil pump. See page 70.
A. Chain and bar. F. Carburettor.
See operating instructions. G. Muffler. See page 49.
B. Starter. See page 57. H. Piston and cylinder. See page 108.
C. Electrical system. See page 61. I. Tank unit. See page 103.
Saws 36, 40, 41 and 45. See next page. Other saws
Saw 394. NOTE!

Ensure that no dirt or foreign particles
enter the bearings.
On saw 394, remove the carburettor

chamber floor (A) and air jet (B).
Other saws.
A
B
Undo the bolts holding the crankcase to-
gether. The bolts are on the clutch side.
Note the location of the bolts that are of a
different length.
Split the crankcase using tool

502 51 61-01.
114 English
Eng, p 83-124 114 96-09-13, 13.02

Press out the crankshaft by using tool

502 51 61-01.
If necessary remove the crankshaft

bearing from the crankcase.
Proceed as follows:
! WARNING!
The crankcase halves can be
hot. Risk of burns. Wear protec-
tive gloves.
Remove all rubber and plastic components

from the crankcase halves.
Saws 36 and 41. Saws 40 and 45. Heat the crankcase half in question to
200C.
Wear protective gloves and knock the

crankcase half gently, inside face down, on
Split the shaft support and a wooden bench or the like, and the
dismantle the halves. bearing will drop out.
Fit the new bearing into the crankcase half

while it is still hot.
If the crankshaft bearing still remains on

the crankshaft when dismantling, remove
it using puller 502 90 90-01.
Remove the bearing from the crankshaft

using puller 502 90 90-01.
If necessary remove the following parts:

A. Chain tension screw
B. Bar bolts
C. Spike
English 115
Eng, p 83-124 115 96-09-13, 13.03

NOTE!
Ensure no dirt or foreign particles
enter the bearings, if fitted in the
crankcase halves.
Clean all parts and scrape of any gasket

residue from the mating surfaces of the
crankcase halves.
Check the following:
That the big end bearing does not have

any radial play. Axial play is acceptable.
That the big end bearing does not have

any score marks or discoloration on the
sides.
That the little end bearing surfaces are not

scored or discoloured.
That the crankshaft bearings do not show

signs of play, have an abnormal noise
level and rotate smoothly.
That the sealing surfaces on the

crankcase seals are not worn and that the
rubber has not hardened.
That the crankcase is not cracked.
116 English
Eng, p 83-124 116 96-09-13, 11.34

Assembly
Saws 36 and 41. Saws 40 and 45. Other saws
See page 120.
Fit the bearing and seals on the crankshaft.

Grease the seals.
Continue assembly as described on
page 111.
! WARNING!
The crankcase halves can be hot.
Risk of burns. Wear protective
gloves.
If the bearing needs to be fitted proceed

as follows:
A. Heat the crankcase half in question to

200C.
B. Wear protective gloves, take out the

crankcase half and press in the bearing.
NOTE!
Ensure that dirt and foreign particles C. Let the crankcase half cool before
do not enter the bearing.
continuing work.
If new seals need to be fitted in the

crankcase, grease the sealing surfaces
and knock in the seals using respective
punchs (see Service tools).
The seals can also be fitted when the

crankcase is in position.
Assembly position. See pages 123 and 124.
English 117
Eng, p 83-124 117 96-09-13, 11.34

Saw 40 and 45. Other saws.
NOTE!
See page 120. Ensure that the connecting rod does
not jam against the crankcase when
the crankcase and crankshaft are
assembled.
Grease and fit a new crankcase gasket (A). Using the assembly tool for the chain saw in
Check that the guide pin (B) is in position and question assemble the crankshaft in the
fit the other crankcase half. clutch sides crankcase half.
Some saws have a sharp edge on the crank-

shaft which can damage the seal. The as-
sembly sleeve should be used when working
on these saws. See Tools.
NOTE! Place the oil tanks vent hose in

the pocket above the tank cap in the
equivalent crankcase half.
NOTE!
Continuing to pull with the assembly
tool after the gasket is clamped will
damage the crankshaft.
Using the assembly tool for the chain saw in

question, fit the two crankcase halves. Pull
until the gasket is clamped between the two
crankcase halves.
118 English
Eng, p 83-124 118 96-09-13, 11.35

Saw 40 and 45. Other saws.
See next page. Fit the crankcase bolts. Tighten crosswise

with the torque set out in the Service data.
Tighten the bolts closest to the crankshaft
first.
NOTE!
Ensure excess gasket material does
not fall into the crankcase.
Cut off excess gasket at the level of the

cylinder seating plane.
On saw 394, fit the floor of the carburettor

chamber using the four bolts.
A
B
Fit the following parts D. Centrifugal clutch. See page 69.

E. Oil pump. See page 77.
A. Chain and bar. See F. Carburettor.
operating instructions. G. Muffler. See page 49.
B. Starter. See page 59. H. Piston and cylinder. See page 111.
C. Electrical system. See page 63. I. Tank unit. See page 105.
If a crankshaft has been fitted the saw must

be run-in for 3-4 hours with the carburettor
set to the basic settings.
English 119
Eng, p 83-124 119 96-09-13, 11.38

Saws 40 and 45.
NOTE!
Ensure that dirt and foreign particles
do not enter the bearing.
Fit the bearing on the crankshaft by using the

assembly tool. See Tools.
Check the shaft seats sealing (A).
Fit the shaft seat over the bearing and join

the shaft seat at (B). A
Continue assembly as described on

page 111.
120 English
Eng, p 83-124 120 96-09-13, 11.38

Bar bolts
When changing the bar bolts on all saws

except 40 and 45 proceed as follows:
1. Drain the chain oil.
2. Knock through the old bar bolt so that it

falls in the oil tank.
3. Remove the bolt from the oil tank.
4. Attach a steel wire to the end of the new

bar bolts, thread the wire through the oil
tank and out through the bolt hole in the
crankcase.
5. Pull the steel wire until the bolt comes

out through its hole.
6. Check that the bolts square shoulder is

aligned with its recess in the crankcase.
Turn the bolt if necessary.
7. Pull through the bolt with its nut and

spacer between the nut and crankcase.
8. Refill with chain oil.
English 121
Eng, p 83-124 121 96-09-13, 11.38

Changing the seals
This section describes how to change the
seals without splitting the crankcase.
Dismantling
Before dismantling the seals remove the

following parts:
On the starter side:

Starter
Flywheel
Generator (if fitted)
On the clutch side:

Chain and bar
Oil pump
Seals fitted in the crankcase
Use the dismantling tool for the saw in

question and remove the seal as follows:
1. Screw the tool into the seals rubber

part.
2. Pull the seal from the crankcase by
turning the handle.
Seals fitted on the oil pump or plastic flange
Press out the seal using a suitable tool.
122 English
Eng, p 83-124 122 96-09-13, 11.39

Assembly
Seal assembly in the oil pump B C
1. Place the oil pump on a sleeve (A) with

an inner diameter greater than the
seals outer diameter.
2. Fit the seal (B) using the assembly

punch so that the surfaces (C), are
level.
A
Seal assembly in the plastic flange
1. Place the plastic flange on a flat and

firm surface.
2. Fit the seal using the assembly punch

until it bottoms on the flange shoulder.
Seal assembly in the crankcase
Some saws have a sharp edge on the crank-

shaft which can damage the seal. The as-
sembly sleeve should be used when working
on these saws. See Tools.
1. Fit the seal using the assembly

mandrel.
2. The seal should be fitted using the

measurements for each saw as shown
in the instructions on the next page.
After fitting the seal assemble:
On the starter side:

Starter
Flywheel
Generator (if fitted)
On the clutch side:

Chain and bar
Oil pump
English 123
Eng, p 83-124 123 96-09-13, 11.39

Assembly positions starter side
Measurement A should be as in the table below

A
for resp. saws (Under the crankcase plane).
61, 268 4-4.5 mm

272 2 mm
281, 288 3.5 mm
Measurement B should be as in the table below

for resp. saws (Under the crankcase plane). B
42, 242, 246 1 mm

394 5 mm
3120 0-0.5 mm
51, 55 1 mm above the

crankcase plane 1 mm
Assembly position on the clutch side
Measurement C should be as in the table below

for resp. saws (Under the crankcase plane). C
51, 55 1 mm
394 0.5 mm
254, 257, 262 1.5 mm above the

1.5 mm
crankcase plane.
124 English
Eng, p 83-124 124 96-09-13, 11.40

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Husqvarna Chain Saws

Eng, front 1 96-09-13, 10.38

Eng, p 2-39 2 96-09-13, 09.05

This workshop manual is written for personnel

The workshop manual should be read and under-

Eng, p 2-39 3 96-09-13, 09.05

5. Order or collect all the required spare

6. In order to Assemble the chain saw,

Refer to pages 117-120 which deals with

Refer to pages 111-112 which deals with

Refer to pages 107 which deals with the

Refer to page 105 which deals with the

Continue to work backwards through the

In order to improve understanding, some

Eng, p 2-39 4 96-09-13, 09.05

Eng, p 2-39 5 96-09-13, 09.05

Displacement Bore Stroke Max. power at

42 42 42.0 30.0 9300

Spark plug gap Ignition system Air gap Carburettor

42 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98

Bar length Chain speed Chain pitch Drive link gauge

36 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050

42 28-46/11-18 17.9/9300 rpm .325 1.5/ .058 / 1.3/ .0501)

Eng, p 2-39 6 96-09-13, 09.05

Idling speed Engagement speed Max. speed Spark plug

42 2700 3800 14500 RCJ 7 Y

36 0.4 7 0.2 Yes

42 0.5 3-7 0.27 Yes

36 4.6 5.3 (13") No

42 4.7 5.5 (13") No

Eng, p 2-39 7 96-09-13, 09.05

Displacement Bore Stroke Max. power at

246 46 44.0 30.0 9000

Spark plug gap Ignition system Air gap Carburettor

246 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98

Bar length Chain speed Chain pitch Drive link gauge

55 38-51/15-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .050 1)

246 28-46/11-18 17.3/9000 rpm .325 1.5/ .058 / 1.3/ .050 1)

Eng, p 2-39 8 96-09-13, 09.05

Idling speed Engagement speed Max. speed Spark plug

246 2700 3900 15000 RCJ 7 Y

55 0.6 10 0.3 Yes

246 0.5 3-7 0.27 Yes

55 5.2 6.2 (15") No

246 4.7 5.5 (13") No

Eng, p 2-39 9 96-09-13, 09.05

Displacemennt Bore Stroke Max. power at

268K 67 50.0 34.0 9000

Spark plug gap Ignition system Air gap Carburettor

268K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255

Bar length Chain speed Chain pitch Drive link gauge

262XP 33-51/13-20 18.5/9600 rpm .325-3/8 1.5/ .058

Eng, p 2-39 10 96-09-13, 09.05

Idling speed Engagement speed Max. speed Spark plug

268K 2500 3500 10000 RCJ 7 Y

262XP 0.6 6.5-13.5 0.3 Yes

262XP 5.8 6.8 (13") 65/10000

Eng, p 2-39 11 96-09-13, 09.43

Displacement Bore Stroke Max. power at

394XP 94 56.0 38.0 8800

Spark plug gap Ignition system Air gap Carburettor

394XP 0.5/ .02 SEM AM 44 0.3/ .012 WALBRO WJ 39

Bar length Chain speed Chain pitch Drive link gauge

compl 502 51 49-02 compl 502 51

502 51 54-01 502 51 54-01

compl 502 51 49-02 compl 502 51 49-02

502 51 54-01 502 51 54-01